Jdub goes there 1981 650e rebuild

[jdub6092]

Tightened up the exhaust clamp on #1. It was a bit loose and will let it go and see if the splotches stop growing.
Now I'm hearing a sound almost like a playing card in the spokes of a bicycle for those of you seasoned enough to remember. Only happens when I accelerate. Goes away as soon as I let off the throttle.
Any clues as to what this might be?

[jdub6092]

Next thing to check for exhaust leak.

[jdub6092]

Compression 1 to 4: 165, 165, 155, 155
Actually pretty impressive.

Spark plugs:
20250322_194549.jpg All look perfect. No indication of lean running on #1.

[jdub6092]

Maybe the blueing of exhaust #1 is trying to tell be something and not just a result of reduced chrome.
Went on a 15 minute ride and it blued up again. I ripped the throttle a couple of times but never got beyond 5k or 55 mph. When I took off, it responded really well, but seemed to drop off a little by the end of the ride.
It was hot enough that the steamy clearish smoke rose from the engine. Not a lot, but clearly visible.
I'm concerned that I may be running extremely lean on #1

20250322_183811.jpg What should I be looking at?
Compression check?
Valve clearance?

[jdub6092]

SH776 all the way, and it's not expensive to buy a good used one from a reputable powersports breaker. They just about never fail, so used is fine.
See if powersportsnation on ebay has one or two up for sale.
Avoid fakes.

I ended up getting an SH775 from Nessism
Works great and runs cool to the touch.
No room for my tool tray now, but at least the battery is charging now.

[Grimly]

So it only looks like I need a new R/R.
I have read the stator papers and I know this topic has been covered endlessly, but would just like some suggestions from those who have been through this. Is it acceptable to just replace the R/R? Is Rick's a good choice for replacement? Is the SH775 better? How about a less expensive alternative?

SH776 all the way, and it's not expensive to buy a good used one from a reputable powersports breaker. They just about never fail, so used is fine.
See if powersportsnation on ebay has one or two up for sale.
Avoid fakes.

[jdub6092]

While I'm finalizing my painting plans, I decided to check out the charging system.
First I checked the resistances of the regulator/rectifier and sure enough, all were an open circuit in both directions. I noticed a nice big burn mark on the red wire insulator and recall from many years ago having a partially melted fusebox.

20250315_150230.jpg
To further evaluate the damage, I measured the resistance of the stator wires and all were around 1.1 ohms. When I had the stator exposed several months back, It did not have any signs of overheating. So far so good.

Then I measured the stator/alternator voltages and all combinations measured over 80VAC at a little over 4K RPM.

So it only looks like I need a new R/R.
I have read the stator papers and I know this topic has been covered endlessly, but would just like some suggestions from those who have been through this. Is it acceptable to just replace the R/R? Is Rick's a good choice for replacement? Is the SH775 better? How about a less expensive alternative?

[jdub6092]

Got a quote for painting. This time it doesn't include a tank and the remaining parts are prepped ( cleaned, stripped, repaired, filled, smoothed) and ready to go. I even supplied the paint and decals.
I think its enough to say that I'll be doing the painting myself.

[jdub6092]

A little surprise after I removed my side cover.
I know it was not like this when I put it on. I guess it could have snapped during riding?

20250308_143450.jpg To top it off I see the front wheel was not removed and obviously not balanced. Has the same stick on weights I put on during static balancing and the speedometer pickup is not parallel to the forks. This was in the work order.

No doubt I need to be my own full time mechanic. I got it all the way to running pretty good with my own hands. I could have done this myself for about the same cost and ended up with new tools. Yes, you all told me so and I'm done overthinking things.

[jdub6092]

Finally got the bike back from the shop after a two hour job that only took 11 days.

The good news is that it starts right up, idles smooths and has all the power I need with no noticeaeble hesitation The owner of the shop said it was quick, nimble and fun to ride.

This was my threshold for going the next step and getting it painted.

The only minor issues I see are:
blueing of exhaust #1 pipe. Not uniform, but a couple of streaky and blotchy patterns near the head. Could be that I removed too much chrome during progressive sanding.
20250308_141641.jpg
This what remains. It was a deep blue before I started polishing it off.
It also leaks a drip of oil every once in a while from the drain bolt, but that's pretty much it.

[jdub6092]

Street legal now! So easy in AZ. Brought in my CA title, filled out a short Title and Registration form, and out in 30 minutes. No wait. No emmissions test. We have lots of DMV contractors that charge a small fee so there is no waiting for 4 hours for your number to be called. Well worth it.

Cant wait to go for an extended ride.

[jdub6092]

Are you going to decal the rest of the bike?

I repainted and polished all the emblems and have the fender and fairings prepped and ready for paint. Already have a pint of photospectrometer color matched PPG paint and all of the decals.

20250217_072210.jpg

Since I found a new tank and dont have any tone matching experience, its almost certain that I'll farm it out to a pro.
Now that the bike is otherwise fully restored and running so well, I'm much less inclined to risk having any regrets.

[650Skull]

Are you going to decal the rest of the bike?

[650Skull]

IMG_20250217_142147.jpg Your seat.......

[650Skull]

Some good news. When starting back up right after the ride, the revs held steady. No Surging.
The sofa seat doesn't quite look right on this bike, but it is comfortable on my old arse. I did order what was supposed to be a GS650E replica.


20250110_163405.jpg

Not that bad, here is my 82Ez
IMG_20250217_055529.jpg